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DOI: 10.1111/cote.12506
ORIGINAL ARTICLE
1
Materials Science and Engineering, Izmir
Katip Celebi University, Izmir, Cigli,
Abstract
Turkey Coloured plastics and polymers are widely used in packaging and consumer goods.
2
Budin Kimyevi Maddeler, Cigli, Izmir, Despite their critical roles, there is limited literature on detailed analysis of effective
Turkey
pigment dispersion in polymer matrices for masterbatch applications. In this study,
Correspondence detailed research was conducted on pigment dispersion using different wax materials
Mehmet Özgür Seydibeyoğlu, Materials and their performances in polyethylene masterbatches were compared. During the
Science and Engineering, Izmir Katip
study, it was first found that the presence of salt crystals plays a critical role in dis-
Celebi University, 35620, Cigli, Izmir,
Turkey. persion in one of the tested pigments. Using a laser particle size device, it was shown
Email: seydibey@gmail.com that homogeneous particle size distribution is another critical parameter for proper
pigment distribution. Although filter testing is a common method in industrial ap-
plications, there is very limited information in the academic literature. The filter test
method was used to examine the effects of different polyethylene waxes on pigment
dispersion. The best filter pressure values were obtained in masterbatches made with
micronised wax. It was also observed that the improved dispersion increased the me-
chanical properties of the masterbatch. The masterbatch colours were measured with
a sphere spectrophotometer and it was observed that uniform pigment distribution
increased the colour strengths. Similar results were also seen in polyethylene films
produced by the blown film process.
pigments. The final step is that the molten resin and wax wet the masterbatches, with a melt flow index (MFI) of 22 g/10 min-
newly formed particles and covers them until the agglomeration utes (190°C and 2.16 kg) and a melting temperature of
ends. This method is called the wetting process.4 105°C. According to the company's technical data sheet, the
Different types of waxes can be used in the wetting process. number average molecular weight (Mn), weight-average mo-
One of the most widely used wax types in the masterbatch in- lecular weight (Mw), and polydispersity index (PDI) values
dustry is polyethylene waxes. These waxes may be homopoly- of LDPE homopolymer were 29 600, 157 000 g/mol, and 5.3,
mers, where the polymer chain is based upon one monomer respectively. The blue pigments with colour index number
unit, such as ethylene, or they may be copolymers, based upon PB15:1, K6902 from BASF (Ludwigshafen, Germany), and
two or more units, such as ethylene and vinyl acetate. These BK828 from Meghmani Organics Ltd (Ahmedabad, India)
types of modified polymer materials contain beneficial adhe- were used. During the experiments, four types of waxes were
sive additives, as they often include polar and non-polar groups used. All waxes, Luwax A (ethylene homopolymer wax),
together on the same molecule, which can function together in Luwax EVA 3 (ethylene copolymer wax), Luwax AF 31
the mixture for stability and adhesion.5,6 Another type of wax (micronised polyethylene wax), and Luwax OA 5 (oxidised
is oxidised polyethylene wax, which is produced by mild air polyethylene wax) were supplied from BASF.
oxidation of polyethylene. It is a polar one, used to prepare
emulsions with various products to improve the quality and per-
formance of the end product.7,8 The particle sizes of waxes are 2.2 | Scanning electron microscopy
generally between 500 and 2000 µm. Particularly when com-
pared to organic pigments, which are between 2 µm and a maxi- Examination of the morphology and distribution of the pig-
mum of 100 µm in size, standard wax particles are much larger. ments and the tensile test specimens were performed by Zeiss
Micronised waxes have an average particle size of between 5 Sigma 300 VP-FESEM scanning electron microscope. The
and 30 µm. This property has a positive effect on pigment dis- samples were coated with gold and images were taken at an ac-
persion during production and processing.9 celerated voltage set to 5 kV. Energy dispersive X-ray (EDX)
Copper phthalocyanine alpha blue (CI Pigment Blue 15:1) analysis was also performed for elemental composition.
is used mainly as a pigment in the masterbatch industry. Its
brilliant blue colour, hiding strength, heat-resistance, weather
resistance, tolerance to the effect of alkali and acids are the 2.3 | Pigment particle size analysis
reason for the widespread use of these pigments.10
In this study, detailed parametric research conducted on Particle sizes of two different pigment samples were meas-
pigment stabilisation, and the effect of different wax types ured with the Horiba LA 350 particle size analyser using ISO
and different pigment grades on the masterbatch dispersion 13320 standard.11
level was investigated. In a laboratory type extruder, widely
used four types of waxes in the masterbatch industry, and
copper phthalocyanine alpha pigments in two different qual- 2.4 | Masterbatch production
ities were mixed with polyethylene matrix and converted
into masterbatches. Mechanical tests, colour comparison Masterbatches were produced using a co-rotating twin-screw
tests, and filter tests were carried out on the masterbatches. extruder LTE-20-44 (Labtech Engineering, Samut Prakan,
Extensive work has been done in the characterisation of pig- Thailand) having a screw diameter of 20 mm and a barrel length
ment dispersion using scanning electron microscopy (SEM). of 880 mm (length/diameter [L/D] = 44). Both pigments were
Masterbatch formulations are often kept secret in the indus- formulated with four different waxes in separate combinations
try, and information on formulations is very limited in the (Table 1). Matrix polymer and other ingredients were mixed
scientific community. Therefore, in this study, we aimed to for 10 minutes in a benchtop high-speed mixer at 2000 rpm.
explain some critical details about the stability of pigments The mixture was fed by the hopper of the extruder with 20 rpm
and characterisation of masterbatches. and the main screw speed was 190 rpm. The zone temperatures
of the extruder were in the range of 140 to 170°C. After the
masterbatches were produced, they were dried at 80 ± 2°C for
2 | E X P ER IME N TA L 1 hour and the moisture they held was removed.
2.1 | Materials
2.5 | Measurement of the quality of dispersion
The base polymer low-density polyethylene (LDPE) was
supplied from Petkim Petrochemical Company (Izmir, To quantify the dispersion, a filter test machine LE20-30/P
Turkey). Petilen I22-19T was used as a matrix material in (Labtech Engineering) having a screw diameter of 20 mm
YÜCETÜRK and SEYdIBEYOĞLU
| 3
was used. The tests were carried out using 15 μm filters, ac- Laboratory Press (Labtech Engineering), which has heating
cording to ISO 23900-5:2015.12 and cooling platens. Tensile test samples were prepared using
Type 1 mould according to the ASTM D638-14 standard.13
10 µm EHT = 5.00 kV Signal A = SE2 Date:15 Apr 2019 10 µm EHT = 5.00 kV Signal A = SE2 Date:15 Apr 2019
WD = 7.5 mm Mag = 2.50 KX Time:11:24:53 WD = 8.5 mm Mag = 2.50 KX Time:11:17:07
The masterbatch and polyethylene blends were made into a 3.1 | Pigment analysis
thin film by a blown film machine (Adali Machine), which
has a 35 mm screw size. To obtain film samples, a 4:1 blow- 3.1.1 | Scanning electron microscopy
up ratio (bur) was used. Briefly, 40 g of masterbatches were
mixed with 960 g of film type polyethylene (Petilen F2-12), In the SEM-analysis of pigments (Figure 1), it was seen
and 120 μ films were produced at 150°C. During and after the that the distribution of BASF K6902 was more homog-
process, agglomerated particles of pigments on the surface enous, and the agglomeration was lower than Meghmani
and inside the films were visually inspected. BK828.
Carbon, copper, and nitrogen elements, in the molecular
structure of the pigment, were found in the EDX analysis.
TABLE 2 Elemental composition of BASF K6902
A certain amount of oxygen was found in both pigments. In
Element Weight (%) Atomic (%) BASF K6902, a low amount of sodium and chlorine elements
Carbon 50.05 59.02 were also found (Table 2).
Nitrogen 25.59 25.88 Higher amounts of nitrogen and lower amounts of oxygen
were found in the Meghmani BK828 pigment. Also, trace
Oxygen 13.77 12.19
amounts of sodium and chlorine in BASF K6902 were not
Sodium 0.73 0.45
found in this pigment (Table 3).
Chlorine 1.46 0.58
The source of these trace elements is probably related to
Copper 8.39 1.87 sodium chloride used during the pigment production pro-
cess. Phthalocyanines must undergo some sort of particle
size reduction by salt milling to achieve better dispersion.
The grinding operation is performed with sodium chloride or
TABLE 3 Elemental composition of Meghmani BK828 other salts at room temperature and in the presence of certain
Element Weight (%) Atomic (%) specified organic solvents.16
After grinding, small amounts of salt can be present with-
Carbon 51.16 59.62
out having a detrimental effect on the process or final pig-
Nitrogen 33.24 33.21
mentary properties. The amount of salt that can be tolerated
Oxygen 5.70 4.98
will depend upon the nature of the salt and the process in
Copper 9.91 2.18 which it is present.17,18
7.0 100
6.0 90
80
Under Size, %
5.0 70
4.0 60
q, %
50
3.0 40
2.0 30
20
1.0 10
0.0 0
F I G U R E 2 Particle size distribution of 0.010 0.100 1.000 10.00 100.0 1000 3000
Meghmani BK828 Diameter, µm
10 100
9 90
8 80
Under Size, %
7 70
6 60
q, %
5 50
4 40
3 30
2 20
1 10
FIGURE 3 Particle size distribution of 0 0
BASF K6902 0.010 0.100 1.000 10.00 100.0 1000 3000
Diameter, µm
YÜCETÜRK and SEYdIBEYOĞLU
| 5
120 115
Particle sizes of the Meghmani BK828 (Figure 2) and BASF 105
100
K6902 (Figure 3) pigments were measured with blue laser 100 95
Color Strenght, %
light using a wet process. According to the histograms, the
particle size distribution of BASF K6902 pigment was more 80
homogeneous than Meghmani BK828.
60
While the BASF pigment only had a slightly smaller par-
ticle size in terms of both mean and median values (Table 4), 40
significant differences in the dispersion results were observed
between the two pigment samples (Figure 4). 20
0
MB1 MB2 MB5 MB9
3.2 | Masterbatch analysis Masterbatch Codes
120 113.5
masterbatches during our study. Also, generally higher re-
sults were obtained in experiments with Meghmani pig- 100
ment. This was because the pigment particle distribution of 80
Meghmani was less homogeneous than BASF pigment. The
60
wax particles in the BASF pigment fulfilled the wetting task
40
14 12
11
12 11.84
11.04 10 9.3 9.3
9.0
Filter Pressure Value, bar/g
9 8.7
Maximum Stress, MPa
10
8.96 8
8 7.76 7.68 7
6
6 5.36 5
3.92 4
4 3.52
3.12 3
2 2
0.88 1
0 0
MB1 MB2 MB3 MB4 MB5 MB6 MB7 MB8 MB9 MB10 MB1 MB2 MB5 MB9
Masterbatch Codes Masterbatch Codes
more successfully. On the contrary, sufficient wetting was need for higher power and shear in the extruder. Since all
not achieved in Meghmani. The weakening of the interfacial masterbatches were produced with the same extruder param-
interactions between polymer and pigment resulted in the eters, the shear was insufficient in masterbatches made with
Meghmani pigment. This, combined with the incompatibil-
110 ity of the wax type, resulted in a comparatively inadequate
100 87.7
dispersion.20
90 81.3
For BASF K6902 and Meghmani BK828, the best filter
80 pressure values (MB5 and MB9) were obtained with a mix-
Strain at Break, %
70
ture of micronised wax. As a result, no wax had a distinct
advantage, except for micronised wax (Figure 4).
60
In the later stages of the study, MB1 and MB2 masterbatches
50
prepared without wax were used as standard, and these master-
40
batches were compared with MB5 and MB9 masterbatches, in
30
which the best results from filter tests were measured.
20 11.9
9.5
10
0 3.2.2 | Colour strength measurement of
MB1 MB2 MB5 MB9 masterbatches
Masterbatch Codes
FIGURE 8 Strain at break of masterbatches The pigment concentration of masterbatches was reduced to
0.2% in LDPE. Relative colour strength was calculated by
100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.9 mm Mag = 100 X Time:14:11:51 WD = 10.2 mm Mag = 100 X Time:14:16:19
100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 100 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.3 mm Mag = 100 X Time:14:18:25 WD = 10.3 mm Mag = 100 x Time:14:20:45
F I G U R E 9 Fractographic studies of tensile test samples with 100× magnification are MB1 (top left), MB2 (top right), MB5 (bottom left),
MB9 (bottom right)
YÜCETÜRK and SEYdIBEYOĞLU
| 7
measuring each sample five times with a spectrophotometer increase in elastic modulus. This was observed with higher
(Figure 5). melting enthalpies in wax-containing blends.22
It was concluded that MB5 and MB9 samples dispersed With the addition of wax, the proportion of polyethylene in
with micronised wax yielded more colour strengths than the formula was reduced. This resulted in increased brittleness
MB1 and MB2 masterbatches without wax in their formu- of samples and reduced elongation (Figure 8). It is explained
las. This result agrees with the results obtained in the filter by Luyt et al.23 that stress is a function of crystallinity, and a
test. Increased pigment dispersion, resulted in a significant decrease in stress is expected with an increase in LDPE content.
decrease in the filter pressure value (FPV) and an increase in The appreciably higher modulus in the samples with higher wax
the relative colour strength.21 content and relatively low LDPE content is also related to the
lower tie-chain fraction that gives rise to more brittle samples.
20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
ED = 12.0 mm Mag = 1.00 KX Time:14:13:36 WD = 10.2 mm Mag = 1.00 KX Time:14:17:20
20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019 20 µm* EHT = 15.00 kV Signal A = HDBSD Date:24 May 2019
WD = 10.3 mm Mag = 1.00 KX Time:14:19:52 WD = 11.0 mm Mag = 1.00 KX Time:14:21:51
F I G U R E 1 0 Fractographic study of tensile test samples with 1.00K× magnification are MB1 (top left), MB2 (top right), MB5 (bottom left),
MB9 (bottom right)
8
| YÜCETÜRK and SEYdIBEYOĞLU
ORCID
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